S0300-BV-CAT-020 HOT TAP SYSTEM. System - P Hot Tap System Overview P /4/ :07:02 AM

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1 Hot Tap System Overview P10100 Page 1

2 The Hot Tap System P10100 consists of two hot tap machines, two heavy duty lightweight hot tap machines, two Mod 2 hydraulic power units, two hydraulic hose reel assemblies, two stud guns, a hydraulic grinder, a hydraulic impact wrench, two 1/2-inch hydraulic drills, a Fluke 87 multimeter, two machinery containment pools, four 16' roundsling bridles, and one container van used for storing and shipping. The Hot Tap System is used underwater by divers to allow oil to be removed from sunken or distressed ships by installing a flange and valve on the side of the ship's hull or tank through which oil can be discharged. This can be accomplished without spilling the oil or admitting water into the tank. When the equipment is in an operating configuration, the storage/shipping container serves as a maintenance shop and personnel shelter. Alternate ESSM configurations are functionally equivalent and are not shown in the catalog. System Components for ESSM No Nomenclature Type Qty NS Cont VA0736A VAN, HOT TAP BL 1 Y CP3010 CONTAINMENT POOL, MCHRY, 10' X 6' X 12" Contents 2 DR0010A DRILL, HYDRAULIC, 1/2", W/MODIFIED TRIGGER S Contents 2 DR0010 DRILL, HYDRAULIC, 1/2" ALTN GU0120 GUN, STUD, HOT TAP SYSTEMS Contents 2 HS0137 HOSE REEL ASSEMBLY, HYDRAULIC, W/3/4" SYNFL Contents 2 HT0006 HOT TAP, 4" LIGHTWEIGHT Contents 2 MC0110 MACHINE, HOT TAP Contents 2 PW0108 POWER UNIT, HYD, MOD 2, DIESEL, Contents 2 TL1000 GRINDER, HYDRAULIC Contents 1 TL1010 WRENCH, IMPACT, HYDRAULIC Contents 1 VA0736C VAN, HOT TAP ALTN Y CP3010 CONTAINMENT POOL, MCHRY, 10' X 6' X 12" Contents 2 GU0120 GUN, STUD, HOT TAP SYSTEMS Contents 2 HS0137 HOSE REEL ASSEMBLY, HYDRAULIC, W/3/4" SYNFL Contents 2 MC0110 MACHINE, HOT TAP Contents 2 PW0108 POWER UNIT, HYD, MOD 2, DIESEL, Contents 2 TL1000 GRINDER, HYDRAULIC Contents 1 TL1010 WRENCH, IMPACT, HYDRAULIC Contents 1 Baseline not verified, * Not shown in catalog. P10100 Alternates Page 2

3 ESSM - VA0736A VAN, HOT TAP Hot Tap Van VA0736A (Exterior) Hot Tap Van VA0736A (Interior) Page 3

4 The Hot Tap Van VA0736A is used as a storage/shipping container for the components of the Hot Tap System, which include two Hydraulic Power Units PW0108, two Hot Tap Machines MC0110, two Stud Guns GU0120, various hydraulic hose assemblies, and the necessary equipment to maintain and operate the Hot Tap System. When the equipment is in an operating configuration, the shipping container serves as a maintenance shop and personnel shelter. The van has a heat pump for climate control, a workbench, and the necessary tools for maintaining the equipment. Commercial Model VA0136A Shipping Length 20 ft, 0 in Width 8 ft, 0 in Height 8 ft, 0 in Cube 1280 cu ft Footprint 160 sq ft Weight lbs References Ref No Reference 1 None Page 4

5 ESSM - CP3010 CONTAINMENT POOL, MCHRY, 10' X 6' X 12" CP3010 Folded Machinery Containment Pool CP3010 The Machinery Containment Pool CP3010 is a 10' x 6' x 12" urethane berm. It is used to provide a means of catching and containing any oil, fuel, or contaminants, leaking or spilled from the operating equipment it contains. Page 5

6 Basic Concepts Model A Shipping Operating Length 3 ft, 3 in 10 ft, 0 in Width 2 ft, 5 in 6 ft, 0 in Height 0 ft, 9 in 1 ft, 0 in Cube 6 cu ft 60 cu ft Footprint 8 sq ft 60 sq ft Weight 70 lbs 70 lbs References Ref No Reference 1 None Page 6

7 ESSM - DR0010A DRILL, HYDRAULIC, 1/2", W/MODIFIED TRIGGER SPRING 1/2" Hydraulic Drill w/modified Trigger Spring DR0010A The 1/2" Hydraulic Drill DR0010A is designed for underwater use and is equipped with a 1/2-inch smooth-jawed adjustable chuck capable of holding drill bits with a shaft size of 1/2 inch in diameter. Manufacture Stanley Model DR07652 Chuck capacity 1/2" Performance gpm gpm gpm gpm gpm Arbor 1" Circuit type Open center Flow Range 3-10 gpm Working pressure psi Full relief setting 2250 psi Hydraulic ports -8 SAE O-ring Page 7

8 Shipping Length 1 ft, 8 in Width 1 ft, 8 in Height 0 ft, 6 in Cube 2 cu ft Footprint 3 sq ft Weight 30 lbs References Ref No Reference 1 Manual, Maintenance and Repair, Diver Tool NAVSEA S9592-AJ-MMA-010 Page 8

9 ESSM - DR0010 DRILL, HYDRAULIC, 1/2" 1/2" Hydraulic Drill DR0010 The 1/2" Hydraulic Drill DR0010 is designed for underwater use and is equipped with a 1/2-inch smooth jawed adjustable chuck capable of holding drill bits with a shaft size of 1/2 inch in diameter. Stanley Model DL09 Drive size 1/2" Hydraulic pressure range psi Flow range 4-12 gpm Optimum flow 8 gpm Porting -8 SAE O-ring Drill speed gpm Rpm range Shipping Length 1 ft, 8 in Page 9

10 Width 1 ft, 8 in Height 0 ft, 6 in Cube 2 cu ft Footprint 3 sq ft Weight 25 lbs References Ref No Reference 1 Hydraulic Drill DL09 Safety, Operation, and Maintenance Manual Page 10

11 ESSM - GU0120 GUN, STUD, HOT TAP SYSTEMS Stud Gun GU0120 The Hot Tap System Stud Gun GU0120 is a direct-acting, high-velocity, underwater marine, powderactuated tool that can be used by divers in water depths to 300 feet. The gun utilizes energy from a special expendable barrel to drive a fastener into steel or concrete. Fasteners are loaded into the expendable barrels prior to entering the water. Once the diver is in the water, the barrel is inserted in the gun and fired. The fastener is driven at a high velocity down the barrel by the expanding gases of the fired load into the work surface. The used barrel is removed and a new barrel is inserted for the next fastening. The stud gun is designed to allow up to four fastenings a minute. I.T.W. Ramset Model 200 HD Caliber.38 Max. depth to use gun 300 ft Velocity of fasteners 492 feet per second Shipping Length 1 ft, 7 in Width 0 ft, 9 in Page 11

12 Height 0 ft, 11 in Cube 1 cu ft Footprint 2 sq ft Weight 30 lbs References Ref No Reference 1 Ramset 200 HD Tool Operator s Instructions and Training Manual, TM-21, 5/88 Page 12

13 ESSM - HS0137 HOSE REEL ASSEMBLY, HYDRAULIC, W/3/4" SYNFLEX HOSE Hose Reel HS0137 The Hydraulic Hose Reel Assembly HS0137 consists of a 3/4-inch diameter braided lined Synflex hose, which is reeled onto a mechanical hose reel in two, 100-foot continuous sections. The hose is equipped with quick disconnect fittings compatible with the Hydraulic Power Unit PW0108. A separate set of 15-foot hose assemblies are used to couple the hoses and the power source to each other. Hose Reel ESSM Facility Model HS0137 Hydraulic Hose Furon Synflex Model 3R80-12 Inner diameter 3/4 in Max. outer diameter 1 in Min. bend radius 7 in Working pressure 2250 psi Min. burst pressure 9000 psi Page 13

14 Weight per 100 feet 26 lb Hose couplings 390 H-12 Length Width Height Cube Footprint Weight References Ref No Reference Shipping 3 ft, 10 in 2 ft, 9 in 3 ft, 11 in 41 cu ft 11 sq ft 630 lb 1 Synflex Hydraulic Hose, Specialty Hose, Tubing, and Accessories; Furon Synflex Reel, 3/4" Hose, Hydraulic NAVSEA Dwg Page 14

15 ESSM - HT0006 HOT TAP, 4" LIGHTWEIGHT 4" Lightweight Hot Tap HT0006 The 4" Lightweight Hot Tap HT0006 has the capability of tapping into mild steel hull plating up to 1 inch thick. The hot tap machine is used to tap a 3 1/2 or a 5 1/2-inch hole through a 6-inch knife valve. The flange/valve assembly through which the tap is accomplished is available in two configurations, a flat surface plate and a contour-forming plate. The flat surface plate is 12 inches in diameter with a 12-inch bolt hole pattern on a 10-inch bolt circle. This plate is used for flat shell or tank top applications. The contour forming plate has a 12-inch by 4-inch base with serrated tabs perpendicular to the base. These tabs can be formed to the contour of the hull. Easy Tapper Model XTC 5.7S Standard tapping range in kit 3 1/2" or 5 1/2" Pressure rating F Method of applied forward pressure Spindle Type of machine-to-valve adapters National Pipe Thread Power pack for cutter rotation Ready for electric, air, or hydraulic power package Page 15

16 Shipping Length 2 ft, 6 in Width 0 ft, 8 in Height 0 ft, 8 in Cube 2 cu ft Footprint 2 sq ft Weight 35 lb References Ref No Reference 1 None Page 16

17 ESSM - MC0110 MACHINE, HOT TAP Hot Tap Machine MC0110 The Hot Tap Machine MC0110 is capable of cutting 5 1/2-inch diameter hole in up to 1-inch thick mild steel plate. The machine is lightweight (with the bulk of its weight concentrated toward the cutter head) and has an adjustable automatic feed rate. These features promote relative ease of handling and operation by divers. The hardware in the kit can restrict the cutting capability to 1-inch plate and 6-inch nominal diameters. The drive motor for the hot tap machine is a hydraulic motor. T.D. Williams, Inc. Model T-203 Max. operating pressure 1500 psi Working pressure psi Flow rate 15 gpm Max. boring bar travel 36" Rate of travel Adjustable: 0 to 1/8" per revolution Nominal cutter size 5 1/2" Pilot size 3/4" diameter Page 17

18 Length Width Height Cube Footprint Weight References Ref No Reference Operating 5 ft, 3 in 2 ft, 2 in 1 ft, 6 in 15 cu ft 12 sq ft 258 lbs 1 T.D. Williams, Inc. Maintenance and Operation Manual, Salvage Hot Tap Kit, NAVCOSSYSCUT, Panama City, FL, May 1978 Page 18

19 ESSM - PW0108 POWER UNIT, HYD, MOD 2, DIESEL, PSI Mod 2 Hydraulic Power Unit PW0108 The Mod 2 Hydraulic Power Unit PW0108 is a portable, diesel driven unit that provides hydraulic fluid up to psi. An adjustable pressure relief valve controls the output pressure delivered to the supply circuit. The HPU is mounted on a steel frame equipped with forklift slots and lifting points for handling during shipment and operation. Hydraulic connections are made via Aeroquip 5600, -12 series male and female quick disconnect fittings for the hydraulic supply and return, with a 3/8-inch case drain fitting. The unit is shipped with the exhaust muffler attached to the side of the HPU housing, and the muffler is installed prior to operation of the unit. Hydraulic Power Unit Assembly Commercial, Navy Design Model NAVSEA Model 2 Diesel Engine Onan Series DJC-MS/2450 Rpm 2400 Horsepower 2400 rpm Starting Electric, 12-volt Page 19

20 Fuel Diesel Fuel source Internal tank, 20-gal Fuel consumption rpm Hydraulic Pump Model Type Flow (maximum) Hyd. reservoir Vickers Inc. 30-H-10 Axial piston psi 55 gal Hydraulic fluid Rando 46 Shipping Operating Shipping w/outward Length 5 ft, 8 in 5 ft, 8 in 5 ft, 8 in Width 2 ft, 0 in 2 ft, 0 in 2 ft, 4 in Height 3 ft, 8 in 3 ft, 8 in 5 ft, 2 in Cube 42 cu ft 42 cu ft 69 cu ft Footprint 12 sq ft 12 sq ft 14 sq ft Weight 1762 lbs 1762 lbs 2035 lb References Ref No Reference 1 Operation and Maintenance Instructions, Diesel Hydraulic Power Unit, NAVSEA Model 2, S9233-A-3- MM0-01B-0910-LP Page 20

21 ESSM - TL1000 GRINDER, HYDRAULIC Hydraulic Grinder TL1000 The Hydraulic Grinder TL1000 is a hydraulically driven rotary device that uses a wheel made of an abrasive material to clean, grind, polish, and shape metallic materials. It is designed for underwater use. Stanley Hydraulic Tools Model GR24 Pressure range psi Flow range 7-9 gpm Optimum flow 9 gpm Porting 3/8" pipe Shipping Length 0 ft, 17 in Width 0 ft, 9 in Height 0 ft, 9 in Cube 1 cu ft Page 21

22 Weight 11 lbs References Ref No Reference 1 Stanley Model GR24 Hydraulic Grinder Parts Manual Page 22

23 ESSM - TL1010 WRENCH, IMPACT, HYDRAULIC, 3/4" Hydraulic Impact Wrench TL1010 The Hydraulic Impact Wrench TL1010 is a rotary hammer that impacts the head of a nut or bolt to either loosen or tighten it and is designed for use underwater. Manufacture Stanley Model IW12340C Capacity 3/4" Torque ft lbs Circuit type Open center Flow Range 4-12 gpm Working pressure psi Full relief setting 2250 psi Hydraulic ports -8 SAE O-ring Shipping Length 1 ft, 8 in Page 23

24 Width 0 ft, 10 in Height 0 ft, 9 in Cube 2 cu ft Footprint 2 sq ft Weight 20 lbs References Ref No Reference 1 Stanley Model IW12 Hydraulic Impact Wrench Parts Manual Page 24

25 ESSM - VA0736C VAN, HOT TAP Hot Tap Van VA0736C The Hot Tap Van VA0736C is used as a storage/shipping container for the components of the Hot Tap System, which include two Hydraulic Power Units PW0108, two Hot Tap Machines MC0110, two Stud Guns GU0120, various hydraulic hose assemblies, and the necessary equipment to maintain and operate the Hot Tap System. When the equipment is in an operating configuration, the shipping container serves as a maintenance shop and personnel shelter. The van has a heat pump for climate control, a workbench, and the necessary tools for maintaining the equipment. Commercial Model VA0736C Shipping Length 20 ft, 0 in Width 8 ft, 0 in Height 8 ft, 0 in Cube 1280 cu ft Footprint 160 sq ft Weight lbs Page 25

26 References Ref No Reference 1 None Page 26

27 ESSM - CP3010 CONTAINMENT POOL, MCHRY, 10' X 6' X 12" CP3010 Folded Machinery Containment Pool CP3010 The Machinery Containment Pool CP3010 is a 10' x 6' x 12" urethane berm. It is used to provide a means of catching and containing any oil, fuel, or contaminants, leaking or spilled from the operating equipment it contains. Page 27

28 Basic Concepts Model A Shipping Operating Length 3 ft, 3 in 10 ft, 0 in Width 2 ft, 5 in 6 ft, 0 in Height 0 ft, 9 in 1 ft, 0 in Cube 6 cu ft 60 cu ft Footprint 8 sq ft 60 sq ft Weight 70 lbs 70 lbs References Ref No Reference 1 None Page 28

29 ESSM - GU0120 GUN, STUD, HOT TAP SYSTEMS Stud Gun GU0120 The Hot Tap System Stud Gun GU0120 is a direct-acting, high-velocity, underwater marine, powderactuated tool that can be used by divers in water depths to 300 feet. The gun utilizes energy from a special expendable barrel to drive a fastener into steel or concrete. Fasteners are loaded into the expendable barrels prior to entering the water. Once the diver is in the water, the barrel is inserted in the gun and fired. The fastener is driven at a high velocity down the barrel by the expanding gases of the fired load into the work surface. The used barrel is removed and a new barrel is inserted for the next fastening. The stud gun is designed to allow up to four fastenings a minute. I.T.W. Ramset Model 200 HD Caliber.38 Max. depth to use gun 300 ft Velocity of fasteners 492 feet per second Shipping Length 1 ft, 7 in Width 0 ft, 9 in Page 29

30 Height 0 ft, 11 in Cube 1 cu ft Footprint 2 sq ft Weight 30 lbs References Ref No Reference 1 Ramset 200 HD Tool Operator s Instructions and Training Manual, TM-21, 5/88 Page 30

31 ESSM - HS0137 HOSE REEL ASSEMBLY, HYDRAULIC, W/3/4" SYNFLEX HOSE Hose Reel HS0137 The Hydraulic Hose Reel Assembly HS0137 consists of a 3/4-inch diameter braided lined Synflex hose, which is reeled onto a mechanical hose reel in two, 100-foot continuous sections. The hose is equipped with quick disconnect fittings compatible with the Hydraulic Power Unit PW0108. A separate set of 15-foot hose assemblies are used to couple the hoses and the power source to each other. Hose Reel ESSM Facility Model HS0137 Hydraulic Hose Furon Synflex Model 3R80-12 Inner diameter 3/4 in Max. outer diameter 1 in Min. bend radius 7 in Working pressure 2250 psi Min. burst pressure 9000 psi Page 31

32 Weight per 100 feet 26 lb Hose couplings 390 H-12 Length Width Height Cube Footprint Weight References Ref No Reference Shipping 3 ft, 10 in 2 ft, 9 in 3 ft, 11 in 41 cu ft 11 sq ft 630 lb 1 Synflex Hydraulic Hose, Specialty Hose, Tubing, and Accessories; Furon Synflex Reel, 3/4" Hose, Hydraulic NAVSEA Dwg Page 32

33 ESSM - MC0110 MACHINE, HOT TAP Hot Tap Machine MC0110 The Hot Tap Machine MC0110 is capable of cutting 5 1/2-inch diameter hole in up to 1-inch thick mild steel plate. The machine is lightweight (with the bulk of its weight concentrated toward the cutter head) and has an adjustable automatic feed rate. These features promote relative ease of handling and operation by divers. The hardware in the kit can restrict the cutting capability to 1-inch plate and 6-inch nominal diameters. The drive motor for the hot tap machine is a hydraulic motor. T.D. Williams, Inc. Model T-203 Max. operating pressure 1500 psi Working pressure psi Flow rate 15 gpm Max. boring bar travel 36" Rate of travel Adjustable: 0 to 1/8" per revolution Nominal cutter size 5 1/2" Pilot size 3/4" diameter Page 33

34 Length Width Height Cube Footprint Weight References Ref No Reference Operating 5 ft, 3 in 2 ft, 2 in 1 ft, 6 in 15 cu ft 12 sq ft 258 lbs 1 T.D. Williams, Inc. Maintenance and Operation Manual, Salvage Hot Tap Kit, NAVCOSSYSCUT, Panama City, FL, May 1978 Page 34

35 ESSM - PW0108 POWER UNIT, HYD, MOD 2, DIESEL, PSI Mod 2 Hydraulic Power Unit PW0108 The Mod 2 Hydraulic Power Unit PW0108 is a portable, diesel driven unit that provides hydraulic fluid up to psi. An adjustable pressure relief valve controls the output pressure delivered to the supply circuit. The HPU is mounted on a steel frame equipped with forklift slots and lifting points for handling during shipment and operation. Hydraulic connections are made via Aeroquip 5600, -12 series male and female quick disconnect fittings for the hydraulic supply and return, with a 3/8-inch case drain fitting. The unit is shipped with the exhaust muffler attached to the side of the HPU housing, and the muffler is installed prior to operation of the unit. Hydraulic Power Unit Assembly Commercial, Navy Design Model NAVSEA Model 2 Diesel Engine Onan Series DJC-MS/2450 Rpm 2400 Horsepower 2400 rpm Starting Electric, 12-volt Page 35

36 Fuel Diesel Fuel source Internal tank, 20-gal Fuel consumption rpm Hydraulic Pump Model Type Flow (maximum) Hyd. reservoir Vickers Inc. 30-H-10 Axial piston psi 55 gal Hydraulic fluid Rando 46 Shipping Operating Shipping w/outward Length 5 ft, 8 in 5 ft, 8 in 5 ft, 8 in Width 2 ft, 0 in 2 ft, 0 in 2 ft, 4 in Height 3 ft, 8 in 3 ft, 8 in 5 ft, 2 in Cube 42 cu ft 42 cu ft 69 cu ft Footprint 12 sq ft 12 sq ft 14 sq ft Weight 1762 lbs 1762 lbs 2035 lb References Ref No Reference 1 Operation and Maintenance Instructions, Diesel Hydraulic Power Unit, NAVSEA Model 2, S9233-A-3- MM0-01B-0910-LP Page 36

37 ESSM - TL1000 GRINDER, HYDRAULIC Hydraulic Grinder TL1000 The Hydraulic Grinder TL1000 is a hydraulically driven rotary device that uses a wheel made of an abrasive material to clean, grind, polish, and shape metallic materials. It is designed for underwater use. Stanley Hydraulic Tools Model GR24 Pressure range psi Flow range 7-9 gpm Optimum flow 9 gpm Porting 3/8" pipe Shipping Length 0 ft, 17 in Width 0 ft, 9 in Height 0 ft, 9 in Cube 1 cu ft Page 37

38 Weight 11 lbs References Ref No Reference 1 Stanley Model GR24 Hydraulic Grinder Parts Manual Page 38

39 ESSM - TL1010 WRENCH, IMPACT, HYDRAULIC, 3/4" Hydraulic Impact Wrench TL1010 The Hydraulic Impact Wrench TL1010 is a rotary hammer that impacts the head of a nut or bolt to either loosen or tighten it and is designed for use underwater. Manufacture Stanley Model IW12340C Capacity 3/4" Torque ft lbs Circuit type Open center Flow Range 4-12 gpm Working pressure psi Full relief setting 2250 psi Hydraulic ports -8 SAE O-ring Shipping Length 1 ft, 8 in Page 39

40 Width 0 ft, 10 in Height 0 ft, 9 in Cube 2 cu ft Footprint 2 sq ft Weight 20 lbs References Ref No Reference 1 Stanley Model IW12 Hydraulic Impact Wrench Parts Manual Page 40